Hand held surgical handle assembly, surgical adapters for use between surgical handle assembly and surgical loading units, and methods of use

ABSTRACT

A surgical device includes an adapter assembly that selectively interconnects a loading unit and a device housing. The adapter assembly includes a drive converter assembly for interconnecting a rotatable drive shaft and an axially translatable drive member of the loading unit. The drive converter assembly converts and transmits a rotation of the rotatable drive shaft to an axial translation of the axially translatable drive member of the loading unit. The drive converter assembly includes a drive element, a drive nut, and a distal drive member. The drive element defines a longitudinal axis. The drive nut is disposed about the longitudinal axis, and the distal drive member is disposed along the longitudinal axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/867,914, filed on Jan. 11, 2018, which is a continuation ofU.S. patent application Ser. No. 13/887,402, filed on May 6, 2013, nowU.S. Pat. No. 9,868,198, which claims the benefit of and priority to aU.S. Provisional Application No. 61/654,206, filed on Jun. 1, 2012, theentire disclosures of all of the foregoing applications are incorporatedby reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to surgical devices and/or systems,surgical adapters and their methods of use. More specifically, thepresent disclosure relates to hand held powered surgical devices,surgical adapters and/or adapter assemblies for use between and forinterconnecting the powered, rotating and/or articulating surgicaldevice or handle assembly and an loading unit for clamping, cuttingand/or stapling tissue.

2. Background of Related Art

One type of surgical device is a linear clamping, cutting and staplingdevice. Such a device may be employed in a surgical procedure to resecta cancerous or anomalous tissue from a gastro-intestinal tract.Conventional linear clamping, cutting and stapling instruments include apistol grip-styled structure having an elongated shaft and distalportion. The distal portion includes a pair of scissors-styled grippingelements, which clamp the open ends of the colon closed. In this device,one of the two scissors-styled gripping elements, such as the anvilportion, moves or pivots relative to the overall structure, whereas theother gripping element remains fixed relative to the overall structure.The actuation of this scissoring device (the pivoting of the anvilportion) is controlled by a grip trigger maintained in the handle.

In addition to the scissoring device, the distal portion also includes astapling mechanism. The fixed gripping element of the scissoringmechanism includes a staple cartridge receiving region and a mechanismfor driving the staples up through the clamped end of the tissue againstthe anvil portion, thereby sealing the previously opened end. Thescissoring elements may be integrally formed with the shaft or may bedetachable such that various scissoring and stapling elements may beinterchangeable.

A number of surgical device manufacturers have developed product lineswith proprietary drive systems for operating and/or manipulating thesurgical device. In many instances the surgical devices include a handleassembly, which is reusable, and a disposable loading unit or the likethat is selectively connected to the handle assembly prior to use andthen disconnected from the loading unit following use in order to bedisposed of or in some instances sterilized for re-use.

Many of the existing loading units for use with many of the existingsurgical devices and/or handle assemblies are driven by a linear force.For examples, loading units for performing endo-gastrointestinalanastomosis procedures, end-to-end anastomosis procedures and transverseanastomosis procedures, each typically require a linear driving force inorder to be operated. As such, these loading units are not compatiblewith surgical devices and/or handle assemblies that use a rotary motionto deliver power or the like.

In order to make the linear driven loading units compatible withsurgical devices and/or handle assemblies that use a rotary motion todeliver power, a need exists for adapters and/or adapter assemblies tointerface between and interconnect the linear driven loading units withthe rotary driven surgical devices and/or handle assemblies.

SUMMARY

The present disclosure relates to a surgical device, comprising a devicehousing, at least one drive motor, a battery, a circuit board, a loadingunit, and an adapter assembly. The device housing defines a connectingportion for selectively connecting with the adapter assembly. The atleast one drive motor is supported in the device housing and isconfigured to rotate at least one drive shaft. The battery is disposedin electrical communication with the at least one drive motor. Thecircuit board is disposed within the housing for controlling powerdelivered from the battery to the at least one drive motor. The loadingunit is configured to perform at least one function, and includes atleast one axially translatable drive member. The adapter assembly is forselectively interconnecting the loading unit and the device housing, andincludes a knob housing, and at least one drive converter assembly. Theknob housing is configured and adapted for selective connection to thedevice housing and to be in operative communication with each of the atleast one rotatable drive shaft. The at least one drive converterassembly is for interconnecting a respective one of the at least onerotatable drive shaft and one of the at least one axially translatabledrive member of the loading unit. The at least one drive converterassembly converts and transmits a rotation of the rotatable drive shaftto an axial translation of the at least one axially translatable drivemember of the loading unit. The at least one drive converter assemblyincludes a first drive converter assembly including a drive element, adrive nut, and a distal drive member. The drive element is rotatablysupported in the knob housing. A proximal end of the drive element isengagable with the rotatable drive shaft. The drive element defines alongitudinal axis. The drive nut is threadably engaged with a distalportion of the drive element. A proximal portion of the distal drivemember is disposed in mechanical cooperation with the drive nut. Adistal portion of the distal drive member is configured for selectiveengagement with the at least one axially translatable drive member ofthe loading unit. Rotation of the rotatable drive shaft results inrotation of the drive element. Rotation of the drive element results inaxial translation of the drive nut, the distal drive member, and the atleast one axially translatable drive member of the loading unit. Thedrive nut is disposed about the longitudinal axis, and the distal drivemember is disposed along the longitudinal axis.

In disclosed embodiments, the threaded portion of the drive element isdisposed along the longitudinal axis.

In disclosed embodiments, a radial center of each of the drive element,the drive nut and the distal drive member are disposed along thelongitudinal axis.

In disclosed embodiments, a radial center of the threaded portion of thedrive element is disposed along the longitudinal axis.

In disclosed embodiments, the entire lengths of each of the driveelement, and the distal drive member are disposed along the longitudinalaxis, and wherein the entire length of the drive nut is disposed aboutthe longitudinal axis.

In disclosed embodiments, the drive element is radially off-center withrespect to the knob housing. Here, it is disclosed that the drive shaftis radially off-center with respect to the connecting portion.

In disclosed embodiments, the drive is rotatable with respect to thedrive nut. Here, it is disclosed that the distal drive member is fixedfrom rotation with respect to the drive nut.

The present disclosure also relates to an adapter assembly forselectively interconnecting a surgical loading unit and a handleassembly having at least one rotatable drive shaft. The adapter assemblycomprises a knob housing, and at least one drive converter assembly. Theknob housing is configured and adapted for selective connection to ahandle assembly, and includes a drive coupling housing. The at least onedrive converter assembly is for interconnecting a respective one of theat least one rotatable drive shaft and a portion of a surgical loadingunit. The at least one drive converter assembly converts and transmits arotation of the rotatable drive shaft to an axial translation of the atleast one axially translatable drive member of the loading unit. The atleast one drive converter assembly includes a first drive converterassembly including a drive element, a drive nut, and a distal drivemember. The drive element is rotatably supported in the knob housing. Aproximal end of the drive element is engagable with the rotatable driveshaft. The drive element defines a longitudinal axis. The drive nut isthreadably engaged with a distal portion of the drive element. Aproximal portion of the distal drive member is disposed in mechanicalcooperation with the drive nut. A distal portion of the distal drivemember is configured for selective engagement with the at least oneaxially translatable drive member of the loading unit. Rotation of therotatable drive shaft results in rotation of the drive element, androtation of the drive element results in axial translation of the drivenut, the distal drive member, and the at least one axially translatabledrive member of the loading unit. The drive nut is disposed about thelongitudinal axis, and the distal drive member is disposed along thelongitudinal axis.

In disclosed embodiments, the threaded portion of the drive element isdisposed along the longitudinal axis.

In disclosed embodiments, a radial center of each of the drive element,the drive nut and the distal drive member are disposed along thelongitudinal axis. Here, it is disclosed that a radial center of thethreaded portion of the drive element is disposed along the longitudinalaxis.

In disclosed embodiments, the entire lengths of each of the driveelement, and the distal drive member are disposed along the longitudinalaxis, and wherein the entire length of the drive nut is disposed aboutthe longitudinal axis.

In disclosed embodiments, the drive element is radially off-center withrespect to the knob housing.

In disclosed embodiments, the drive is rotatable with respect to thedrive nut. Here, it is disclosed that the distal drive member is fixedfrom rotation with respect to the drive nut.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1 is a perspective view, with parts separated, of a surgical deviceand adapter, in accordance with an embodiment of the present disclosure,illustrating a connection thereof with an loading unit;

FIG. 2 is a perspective view of the surgical device of FIG. 1 ;

FIG. 3 is a perspective view, with parts separated, of the surgicaldevice of FIGS. 1 and 2 ;

FIG. 4 is a perspective view of a battery for use in the surgical deviceof FIGS. 1-3 ;

FIG. 5 is a perspective view of the surgical device of FIGS. 1-3 , witha housing thereof removed;

FIG. 6 is a perspective view of the connecting ends of each of thesurgical device and the adapter, illustrating a connection therebetween;

FIG. 7 is a cross-sectional view of the surgical device of FIGS. 1-3 ,as taken through 7-7 of FIG. 2 ;

FIG. 8 is a cross-sectional view of the surgical device of FIGS. 1-3 ,as taken through 8-8 of FIG. 2 ;

FIG. 9 is a perspective view, with parts separated, of a trigger housingof the surgical device of FIGS. 1-3 ;

FIG. 10 is a perspective view of the adapter of FIG. 1 ;

FIG. 11 is an end view of the adapter of FIGS. 1 and 10 , as seen from11-11 of FIG. 10 ;

FIG. 12 is a cross-sectional view of the adapter of FIGS. 1 and 10 , astaken through 12-12 of FIG. 10 ;

FIG. 13 is an enlarged view of the indicated area of detail of FIG. 12 ;

FIG. 14 is an enlarged view of the indicated area of detail of FIG. 12 ;

FIG. 15 is a cross-sectional view of the adapter of FIGS. 1 and 10 , astaken through 15-15 of FIG. 12 ;

FIG. 16 is an enlarged view of the indicated area of detail of FIG. 15 ;

FIG. 17 is an enlarged view of the indicated area of detail of FIG. 15 ;

FIG. 18 is a cross-sectional view of the adapter of FIGS. 1 and 10 , astaken through 18-18 of FIG. 17 ;

FIG. 19 is an enlarged view of the indicated area of detail of FIG. 15 ;

FIG. 20 is a perspective view of a firing system of the presentdisclosure;

FIG. 21 is a longitudinal cross-sectional view of the firing system ofFIG. 20 ;

FIG. 22 is an enlarged view of the indicated area of detail of FIG. 21 ;

FIG. 23 is an enlarged view of the indicated area of detail of FIG. 20 ;

FIG. 24 is a perspective view of a distal portion of the adapter ofFIGS. 1 and 10 adjacent a proximal portion of a loading unit;

FIG. 25 is a perspective view, with parts separated, of an exemplaryloading unit for use with the surgical device and the adapter of thepresent disclosure; and

FIG. 26 is a schematic illustration of the outputs to the LEDs;selection of motor (to select clamping/cutting, rotation orarticulation); and selection of the drive motors to perform a functionselected.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical devices, and adapterassemblies for surgical devices and/or handle assemblies are describedin detail with reference to the drawings, in which like referencenumerals designate identical or corresponding elements in each of theseveral views. As used herein the term “distal” refers to that portionof the adapter assembly or surgical device, or component thereof,farther from the user, while the term “proximal” refers to that portionof the adapter assembly or surgical device, or component thereof, closerto the user.

A surgical device, in accordance with an embodiment of the presentdisclosure, is generally designated as 100, and is in the form of apowered hand held electromechanical instrument configured for selectiveattachment thereto of a plurality of different loading units that areeach configured for actuation and manipulation by the powered hand heldelectromechanical surgical instrument.

As illustrated in FIG. 1 , surgical device 100 is configured forselective connection with an adapter 200, and, in turn, adapter 200 isconfigured for selective connection with an loading unit or single useloading unit 300.

As illustrated in FIGS. 1-3 , surgical device 100 includes a handlehousing 102 having a lower housing portion 104, an intermediate housingportion 106 extending from and/or supported on lower housing portion104, and an upper housing portion 108 extending from and/or supported onintermediate housing portion 106. Intermediate housing portion 106 andupper housing portion 108 are separated into a distal half-section 110 athat is integrally formed with and extending from the lower portion 104,and a proximal half-section 110 b connectable to distal half-section 110a by a plurality of fasteners. When joined, distal and proximalhalf-sections 110 a, 110 b define a handle housing 102 having a cavity102 a therein in which a circuit board 150 and a drive mechanism 160 issituated.

Distal and proximal half-sections 110 a, 110 b are divided along a planethat traverses a longitudinal axis “X” of upper housing portion 108, asseen in FIG. 3 .

Handle housing 102 includes a gasket 112 extending completely around arim of distal half-section and/or proximal half-section 110 a, 110 b andbeing interposed between distal half-section 110 a and proximalhalf-section 110 b. Gasket 112 seals the perimeter of distalhalf-section 110 a and proximal half-section 110 b. Gasket 112 functionsto establish an air-tight seal between distal half-section 110 a andproximal half-section 110 b such that circuit board 150 and drivemechanism 160 are protected from sterilization and/or cleaningprocedures.

In this manner, the cavity 102 a of handle housing 102 is sealed alongthe perimeter of distal half-section 110 a and proximal half-section 110b yet is configured to enable easier, more efficient assembly of circuitboard 150 and a drive mechanism 160 in handle housing 102.

Intermediate housing portion 106 of handle housing 102 provides ahousing in which circuit board 150 is situated. Circuit board 150 isconfigured to control the various operations of surgical device 100, aswill be set forth in additional detail below.

Lower housing portion 104 of surgical device 100 defines an aperture(not shown) formed in an upper surface thereof and which is locatedbeneath or within intermediate housing portion 106. The aperture oflower housing portion 104 provides a passage through which wires 152pass to electrically interconnect electrical components (a battery 156,as illustrated in FIG. 4 , a circuit board 154, as illustrated in FIG. 3, etc.) situated in lower housing portion 104 with electrical components(circuit board 150, drive mechanism 160, etc.) situated in intermediatehousing portion 106 and/or upper housing portion 108.

Handle housing 102 includes a gasket 103 disposed within the aperture oflower housing portion 104 (not shown) thereby plugging or sealing theaperture of lower housing portion 104 while allowing wires 152 to passtherethrough. Gasket 103 functions to establish an air-tight sealbetween lower housing portion 106 and intermediate housing portion 108such that circuit board 150 and drive mechanism 160 are protected fromsterilization and/or cleaning procedures.

As shown, lower housing portion 104 of handle housing 102 provides ahousing in which a rechargeable battery 156, is removably situated.Battery 156 is configured to supply power to any of the electricalcomponents of surgical device 100. Lower housing portion 104 defines acavity (not shown) into which battery 156 is inserted. Lower housingportion 104 includes a door 105 pivotally connected thereto for closingcavity of lower housing portion 104 and retaining battery 156 therein.

With reference to FIGS. 3 and 5 , distal half-section 110 a of upperhousing portion 108 defines a nose or connecting portion 108 a. A nosecone 114 is supported on nose portion 108 a of upper housing portion108. Nose cone 114 is fabricated from a transparent material. Anillumination member 116 is disposed within nose cone 114 such thatillumination member 116 is visible therethrough. Illumination member 116is in the form of a light emitting diode printed circuit board (LEDPCB). Illumination member 116 is configured to illuminate multiplecolors with a specific color pattern being associated with a uniquediscrete event.

Upper housing portion 108 of handle housing 102 provides a housing inwhich drive mechanism 160 is situated. As illustrated in FIG. 5 , drivemechanism 160 is configured to drive shafts and/or gear components inorder to perform the various operations of surgical device 100. Inparticular, drive mechanism 160 is configured to drive shafts and/orgear components in order to selectively move tool assembly 304 ofloading unit 300 (see FIGS. 1 and 20 ) relative to proximal body portion302 of loading unit 300, to rotate loading unit 300 about a longitudinalaxis “X” (see FIG. 3 ) relative to handle housing 102, to move anvilassembly 306 relative to cartridge assembly 308 of loading unit 300,and/or to fire a stapling and cutting cartridge within cartridgeassembly 308 of loading unit 300.

The drive mechanism 160 includes a selector gearbox assembly 162 that islocated immediately proximal relative to adapter 200. Proximal to theselector gearbox assembly 162 is a function selection module 163 havinga first motor 164 that functions to selectively move gear elementswithin the selector gearbox assembly 162 into engagement with an inputdrive component 165 having a second motor 166.

As illustrated in FIGS. 1-4 , and as mentioned above, distalhalf-section 110 a of upper housing portion 108 defines a connectingportion 108 a configured to accept a corresponding drive couplingassembly 210 of adapter 200.

As illustrated in FIGS. 6-8 , connecting portion 108 a of surgicaldevice 100 has a cylindrical recess 108 b that receives a drive couplingassembly 210 of adapter 200 when adapter 200 is mated to surgical device100. Connecting portion 108 a houses three rotatable drive connectors118, 120, 122.

When adapter 200 is mated to surgical device 100, each of rotatabledrive connectors 118, 120, 122 of surgical device 100 couples with acorresponding rotatable connector sleeve 218, 220, 222 of adapter 200.(see FIG. 6 ). In this regard, the interface between corresponding firstdrive connector 118 and first connector sleeve 218, the interfacebetween corresponding second drive connector 120 and second connectorsleeve 220, and the interface between corresponding third driveconnector 122 and third connector sleeve 222 are keyed such thatrotation of each of drive connectors 118, 120, 122 of surgical device100 causes a corresponding rotation of the corresponding connectorsleeve 218, 220, 222 of adapter 200.

The mating of drive connectors 118, 120, 122 of surgical device 100 withconnector sleeves 218, 220, 222 of adapter 200 allows rotational forcesto be independently transmitted via each of the three respectiveconnector interfaces. The drive connectors 118, 120, 122 of surgicaldevice 100 are configured to be independently rotated by drive mechanism160. In this regard, the function selection module 163 of drivemechanism 160 selects which drive connector or connectors 118, 120, 122of surgical device 100 is to be driven by the input drive component 165of drive mechanism 160.

Since each of drive connectors 118, 120, 122 of surgical device 100 hasa keyed and/or substantially non-rotatable interface with respectiveconnector sleeves 218, 220, 222 of adapter 200, when adapter 200 iscoupled to surgical device 100, rotational force(s) are selectivelytransferred from drive mechanism 160 of surgical device 100 to adapter200.

The selective rotation of drive connector(s) 118, 120 and/or 122 ofsurgical device 100 allows surgical device 100 to selectively actuatedifferent functions of loading unit 300. As will be discussed in greaterdetail below, selective and independent rotation of first driveconnector 118 of surgical device 100 corresponds to the selective andindependent opening and closing of tool assembly 304 of loading unit300, and driving of a stapling/cutting component of tool assembly 304 ofloading unit 300. Also, the selective and independent rotation of seconddrive connector 120 of surgical device 100 corresponds to the selectiveand independent articulation of tool assembly 304 of loading unit 300transverse to longitudinal axis “X” (see FIG. 3 ). Additionally, theselective and independent rotation of third drive connector 122 ofsurgical device 100 corresponds to the selective and independentrotation of loading unit 300 about longitudinal axis “X” (see FIG. 3 )relative to handle housing 102 of surgical device 100.

As mentioned above and as illustrated in FIGS. 5 and 8 , drive mechanism160 includes a selector gearbox assembly 162; a function selectionmodule 163, located proximal to the selector gearbox assembly 162, thatfunctions to selectively move gear elements within the selector gearboxassembly 162 into engagement with second motor 166. Thus, drivemechanism 160 selectively drives one of drive connectors 118, 120, 122of surgical device 100 at a given time.

As illustrated in FIGS. 1-3 and FIG. 9 , handle housing 102 supports atrigger housing 107 on a distal surface or side of intermediate housingportion 108. Trigger housing 107, in cooperation with intermediatehousing portion 108, supports a pair of finger-actuated control buttons124, 126 and rocker devices 128, 130. In particular, trigger housing 107defines an upper aperture 124 a for slidably receiving a first controlbutton 124, and a lower aperture 126 b for slidably receiving a secondcontrol button 126.

Each one of the control buttons 124, 126 and rocker devices 128, 130includes a respective magnet (not shown) that is moved by the actuationof an operator. In addition, circuit board 150 includes, for each one ofthe control buttons 124, 126 and rocker devices 128, 130, respectiveHall-effect switches 150 a-150 d that are actuated by the movement ofthe magnets in the control buttons 124, 126 and rocker devices 128, 130.In particular, located immediately proximal to the control button 124 isa first Hall-effect switch 150 a (see FIGS. 3 and 7 ) that is actuatedupon the movement of a magnet within the control button 124 upon theoperator actuating control button 124. The actuation of firstHall-effect switch 150 a, corresponding to control button 124, causescircuit board 150 to provide appropriate signals to function selectionmodule 163 and input drive component 165 of the drive mechanism 160 toclose a tool assembly 304 of loading unit 300 and/or to fire astapling/cutting cartridge within tool assembly 304 of loading unit 300.

Also, located immediately proximal to rocker device 128 is a secondHall-effect switch 150 b (see FIGS. 3 and 7 ) that is actuated upon themovement of a magnet (not shown) within rocker device 128 upon theoperator actuating rocker device 128. The actuation of secondHall-effect switch 150 b, corresponding to rocker device 128, causescircuit board 150 to provide appropriate signals to function selectionmodule 163 and input drive component 165 of drive mechanism 160 toarticulate tool assembly 304 relative to body portion 302 of loadingunit 300. Advantageously, movement of rocker device 128 in a firstdirection causes tool assembly 304 to articulate relative to bodyportion 302 in a first direction, while movement of rocker device 128 inan opposite, e.g., second, direction causes tool assembly 304 toarticulate relative to body portion 302 in an opposite, e.g., second,direction.

Furthermore, located immediately proximal to control button 126 is athird Hall-effect switch 150 c (see FIGS. 3 and 7 ) that is actuatedupon the movement of a magnet (not shown) within control button 126 uponthe operator actuating control button 126. The actuation of thirdHall-effect switch 150 c, corresponding to control button 126, causescircuit board 150 to provide appropriate signals to function selectionmodule 163 and input drive component 165 of drive mechanism 160 to opentool assembly 304 of loading unit 300.

In addition, located immediately proximal to rocker device 130 is afourth Hall-effect switch 150 d (see FIGS. 3 and 7 ) that is actuatedupon the movement of a magnet (not shown) within rocker device 130 uponthe operator actuating rocker device 130. The actuation of fourthHall-effect switch 150 d, corresponding to rocker device 130, causescircuit board 150 to provide appropriate signals to function selectionmodule 163 and input drive component 165 of drive mechanism 160 torotate loading unit 300 relative to handle housing 102 surgical device100. Specifically, movement of rocker device 130 in a first directioncauses loading unit 300 to rotate relative to handle housing 102 in afirst direction, while movement of rocker device 130 in an opposite,e.g., second, direction causes loading unit 300 to rotate relative tohandle housing 102 in an opposite, e.g., second, direction.

As seen in FIGS. 1-3 , surgical device 100 includes a fire button orsafety switch 132 supported between intermediate housing portion 108 andupper housing portion, and situated above trigger housing 107. In use,tool assembly 304 of loading unit 300 is actuated between opened andclosed conditions as needed and/or desired. In order to fire loadingunit 300, to expel fasteners therefrom when tool assembly 304 of loadingunit 300 is in a closed condition, safety switch 132 is depressedthereby instructing surgical device 100 that loading unit 300 is readyto expel fasteners therefrom.

As illustrated in FIGS. 1 and 10-24 , surgical device 100 is configuredfor selective connection with adapter 200, and, in turn, adapter 200 isconfigured for selective connection with loading unit 300.

Adapter 200 is configured to convert a rotation of either of driveconnectors 120 and 122 of surgical device 100 into axial translationuseful for operating a drive assembly 360 and an articulation link 366of loading unit 300, as illustrated in FIG. 25 and as will be discussedin greater detail below.

Adapter 200 includes a first drive transmitting/converting assembly forinterconnecting third rotatable drive connector 122 of surgical device100 and a first axially translatable drive member 360 of loading unit300, wherein the first drive transmitting/converting assembly convertsand transmits a rotation of third rotatable drive connector 122 ofsurgical device 100 to an axial translation of the first axiallytranslatable drive assembly 360 of loading unit 300 for firing.

Adapter 200 includes a second drive transmitting/converting assembly forinterconnecting second rotatable drive connector 120 of surgical device100 and a second axially translatable drive member 366 of loading unit300, wherein the second drive transmitting/converting assembly convertsand transmits a rotation of second rotatable drive connector 120 ofsurgical device 100 to an axial translation of articulation link 366 ofloading unit 300 for articulation.

Turning now to FIG. 10 , adapter 200 includes a knob housing 202 and anouter tube 206 extending from a distal end of knob housing 202. Knobhousing 202 and outer tube 206 are configured and dimensioned to housethe components of adapter 200. Outer tube 206 is dimensioned forendoscopic insertion, in particular, that outer tube is passable througha typical trocar port, cannula or the like. Knob housing 202 isdimensioned to not enter the trocar port, cannula of the like. Knobhousing 202 is configured and adapted to connect to connecting portion108 a of upper housing portion 108 of distal half-section 110 a ofsurgical device 100.

As seen in FIGS. 10, 12 and 15 , adapter 200 includes a surgical devicedrive coupling assembly 210 at a proximal end thereof and an loadingunit coupling assembly 230 at a distal end thereof. Drive couplingassembly 210 includes a drive coupling housing 210 a rotatablysupported, at least partially, in knob housing 202. In the illustratedembodiments, drive coupling assembly 210 rotatably supports a firstrotatable proximal drive shaft or element 212.

As seen in FIGS. 6 and 11 , drive coupling housing 210 a is configuredto rotatably support first, second and third connector sleeves 218, 220and 222, respectively. Each of connector sleeves 218, 220, 222 isconfigured to mate with respective first, second and third driveconnectors 118, 120, 122 of surgical device 100, as described above.Connector sleeve 220 is also configured to mate with a proximal end offirst proximal drive shaft 212. It is further envisioned that connectorsleeves 218 and 222 are configured to mate with a proximal end of asecond proximal drive shaft and a third proximal drive shaft,respectively.

With particular reference to FIGS. 13 and 16 , proximal drive couplingassembly 210 includes a biasing member 224 disposed distally ofrespective connector sleeve 220. Biasing member 224 is disposed aboutdrive shaft 212. Biasing member 224 acts on connector sleeve 220 to helpmaintain connector sleeve 220 engaged with the distal end of rotatabledrive connector 118 of surgical device 100 when adapter 200 is connectedto surgical device 100.

In particular, biasing member 224 functions to bias connector sleeve 220in a proximal direction. In this manner, during assembly of adapter 200to surgical device 100, if connector sleeve 220 is misaligned with thedrive connector 120 of surgical device 100, biasing member 224 iscompressed. Thus, when drive mechanism 160 of surgical device 100 isengaged, drive connector 120 of surgical device 100 will rotate andbiasing member 224 will cause connector sleeve 220 to slide backproximally, effectively coupling drive connector 120 of surgical device100 to proximal drive shaft 212 of proximal drive coupling assembly 210.It is further envisioned that drive coupling assembly 210 includesrespective biasing members for proximally biasing each connector sleeve218, 222 into engagement with the distal end of respective rotatabledrive connectors 118, 122.

Adapter 200, as seen in FIGS. 12, 15, 20 and 21 , includes a drivetransmitting/converting assembly 240 disposed within handle housing 202and outer tube 206. Drive transmitting/converting assembly 240 isconfigured and adapted to transmit or convert a rotation of driveconnector 120 of surgical device 100 into axial translation of a distaldrive member 248 of adapter 200, to effectuate closing, opening, andfiring of loading unit 300.

As seen in FIGS. 12-24 , and particularly FIGS. 20-23 , first drivetransmitting/converting assembly 240 includes drive shaft 212, a leadscrew 250, a drive nut 260, and distal drive member 248. Lead screw 250is a threaded portion 252, distally disposed on drive shaft 212. Drivenut 260 is an elongated member and includes an internal threaded portion262 along an internal periphery of at least a portion of its length(e.g., proximal portion 262 a). Threaded portion 262 of drive nut 260 isconfigured to mechanically engage threaded portion 252 of lead screw250. A proximal portion 248 a of distal drive member 248 is disposed inmechanical cooperation with a distal portion 260 b of drive nut 260 viaa linking assembly 270.

In particular, with regard to FIGS. 15, 17 and 18 , linking assembly 270includes a first pin 272 a and a second pin 272 b disposedperpendicularly from a longitudinal axis B-B defined by drive shaft 212.Each pin 272 extends through a groove 264 (FIG. 17 ), which extends atleast partially through drive nut 260, and a pair of correspondingrecesses 249 (FIG. 18 ) extending at least partially through distaldrive member 248. Additionally, a proximal portion 248 a of distal drivemember 248 is disposed within a socket 266 formed within a distalportion 260 b of drive nut 260. Further, distal drive member 248includes a stop member 247 disposed adjacent proximal portion 248 athereof, which is configured to help limit distal translation of drivenut 260 with respect to distal drive member 248, for instance.Accordingly, linking assembly 270, including pins 272, effectivelycouples drive nut 260 with distal drive member 248, such thatlongitudinal translation of drive nut 260 causes concomitantlongitudinal translation of distal drive member 248.

Further, with particular reference to FIG. 18 , at least a portion ofthe perimeter of drive nut 260 includes an anti-rotation section 261.Section 261 is shown including flat surfaces, which are disposed on twolateral sides of drive nut 260 and adjacent similarly-shaped surfaces201 of an interior portion of adapter 200. Thus, while rotation of driveshaft 212 causes rotation of lead screw 250, and while rotation of leadscrew 250 would ordinarily causes rotation and longitudinal translationof drive nut 260, anti-rotation section 261 of drive nut 260 eliminatesthe rotation component of its movement. Thus, rotation of drive shaft212 causes a non-rotational, longitudinal translation of drive nut 260,and thus distal drive member 248.

With reference to FIGS. 20-23 , first drive transmitting/convertingassembly 240 also includes a pair of thrust bearings 280. In theillustrated embodiment, thrust bearings 280 are disposedcircumferentially surrounding a portion of drive shaft 212, proximallyof lead screw 250. Additionally, drive shaft 212 is shown including anenlarged-diameter ring or flange 215 disposed between a first thrustbearing 280 a and a second thrust bearing 280 b. It is envisioned thatthrust bearings 280 facilitate rotation of drive shaft 212 with respectto drive coupling housing 210 a, while maintaining the ability to rotatewhen drive shaft 212 is subjected to axial forces (e.g., when jawmembers of end effector 300 are clamping tissue, etc.)

As shown in FIG. 21 , longitudinal axis B-B extends through a radialcenter of drive shaft 212, a radial center of lead screw 250, a radialcenter of drive nut 260 (i.e., drive nut 260 is disposed aboutlongitudinal axis B-B), and a radial center of distal drive member 248.Further, longitudinal axis B-B extends through the radial centers ofdrive shaft 212, lead screw 250, drive nut 260, and distal drive member248 along the entirety of their respective lengths. This orientation ofthe so-called “on center drive system” allows distal drive member 248 tobe driven directly from a motor (first motor 164, for example) and doesnot require any gears, thus reducing complexity and costs that aregenerally associated from a geared assembly. Additionally, since driveshaft 212 and lead screw 250 are under the same torque load, accuratemonitoring of the torque from handle housing 102 can be facilitated.

In use, rotation of drive shaft 212, causes rotation of lead screw 250,which results in longitudinal translation of drive nut 260 alonglongitudinal axis B-B defined by drive shaft 212, which causeslongitudinal translation of distal drive member 248. When end effector300 is engaged with adapter 200, longitudinal translation of distaldrive member 248 causes concomitant axial translation of drive member374 of loading unit 300 to effectuate a closure of tool assembly 304 anda firing of tool assembly 304 of loading unit 300.

As seen in FIG. 6 , adapter 200 includes a pair of electrical contactpins 290 a, 290 b for electrical connection to a correspondingelectrical plug 190 a, 190 b disposed in connecting portion 108 a ofsurgical device 100. Electrical contacts 290 a, 290 b serve to allow forcalibration and communication of life-cycle information to circuit board150 of surgical device 100 via electrical plugs 190 a, 190 b that areelectrically connected to circuit board 150. Adapter 200 furtherincludes a circuit board supported in knob housing 202 and which is inelectrical communication with electrical contact pins 290 a, 290 b.

When a button of surgical device is activated by the user, the softwarechecks predefined conditions. If conditions are met, the softwarecontrols the motors and delivers mechanical drive to the attachedsurgical stapler, which can then open, close, rotate, articulate or firedepending on the function of the pressed button. The software alsoprovides feedback to the user by turning colored lights on or off in adefined manner to indicate the status of surgical device 100, adapter200 and/or loading unit 300.

A high level electrical architectural view of the system is shown inFIG. 26 and shows the connections to the various hardware and softwareinterfaces. Inputs from presses of buttons 124, 126 and from motorencoders of the drive shaft are shown on the left side of FIG. 26 . Themicrocontroller contains the device software that operates surgicaldevice 100, adapter 200 and/or loading unit 300. The microcontrollerreceives inputs from and sends outputs to a MicroLAN, an Ultra ID chip,a Battery ID chip, and Adaptor ID chips. The MicroLAN, the Ultra IDchip, the Battery ID chip, and the Adaptor ID chips control surgicaldevice 100, adapter 200 and/or loading unit 300 as follows:

MicroLAN Serial 1-wire bus communication to read/write system componentID information. Ultra ID chip identifies surgical device 100 and recordsusage information. Battery ID chip identifies the Battery 156 andrecords usage information. Adaptor ID chip identifies the type ofadapter 200, records the presence of an end effector 300, and recordsusage information.

The right side of the schematic illustrated in FIG. 26 indicates outputsto the LEDs; selection of motor (to select clamping/cutting, rotation orarticulation); and selection of the drive motors to perform the functionselected.

As illustrated in FIGS. 1 and 25 , the loading unit is designated as300. Loading unit 300 is configured and dimensioned for endoscopicinsertion through a cannula, trocar or the like. In particular, in theembodiment illustrated in FIGS. 1 and 25 , loading unit 300 may passthrough a cannula or trocar when loading unit 300 is in a closedcondition.

Loading unit 300 includes a proximal body portion 302 and a toolassembly 304. Proximal body portion 302 is releasably attached to adistal coupling 230 of adapter 200 and tool assembly 304 is pivotallyattached to a distal end of proximal body portion 302. Tool assembly 304includes an anvil assembly 306 and a cartridge assembly 308. Cartridgeassembly 308 is pivotal in relation to anvil assembly 306 and is movablebetween an open or unclamped position and a closed or clamped positionfor insertion through a cannula of a trocar.

Proximal body portion 302 includes at least a drive assembly 360 and anarticulation link 366.

Referring to FIG. 25 , drive assembly 360 includes a flexible drive beam364 having a distal end which is secured to a dynamic clamping member365, and a proximal engagement section 368. Engagement section 368includes a stepped portion defining a shoulder 370. A proximal end ofengagement section 368 includes diametrically opposed inwardly extendingfingers 372. Fingers 372 engage a hollow drive member 374 to fixedlysecure drive member 374 to the proximal end of beam 364. Drive member374 defines a proximal porthole 376 which receives connection member 247of drive tube 246 of first drive converter assembly 240 of adapter 200when loading unit 300 is attached to distal coupling 230 of adapter 200.

When drive assembly 360 is advanced distally within tool assembly 304,an upper beam of clamping member 365 moves within a channel definedbetween anvil plate 312 and anvil cover 310 and a lower beam moves overthe exterior surface of carrier 316 to close tool assembly 304 and firestaples therefrom.

Proximal body portion 302 of loading unit 300 includes an articulationlink 366 having a hooked proximal end 366 a which extends from aproximal end of loading unit 300. Hooked proximal end 366 a ofarticulation link 366 engages coupling hook 258 c of drive bar 258 ofadapter 200 when loading unit 300 is secured to distal housing 232 ofadapter 200. When drive bar 258 of adapter 200 is advanced or retractedas described above, articulation link 366 of loading unit 300 isadvanced or retracted within loading unit 300 to pivot tool assembly 304in relation to a distal end of proximal body portion 302.

As illustrated in FIG. 25 , cartridge assembly 308 of tool assembly 304includes a staple cartridge 305 supportable in carrier 316. Staplecartridge 305 defines a central longitudinal slot 305 a, and threelinear rows of staple retention slots 305 b positioned on each side oflongitudinal slot 305 a. Each of staple retention slots 305 b receives asingle staple 307 and a portion of a staple pusher 309. During operationof surgical device 100, drive assembly 360 abuts an actuation sled andpushes actuation sled through cartridge 305. As the actuation sled movesthrough cartridge 305, cam wedges of the actuation sled sequentiallyengage staple pushers 309 to move staple pushers 309 vertically withinstaple retention slots 305 b and sequentially eject a single staple 307therefrom for formation against anvil plate 312.

Reference may be made to U.S. Pat. No. 7,819,896 for a detaileddiscussion of the construction and operation of loading unit 300.

It will be understood that various modifications may be made to theembodiments of the presently disclosed adapter assemblies. For example,the battery 156 may be replaced with alternate sources of electricalpower such as line voltage (either AC or DC) or a fuel cell. Therefore,the above description should not be construed as limiting, but merely asexemplifications of embodiments. Those skilled in the art will envisionother modifications within the scope and spirit of the presentdisclosure.

What is claimed is:
 1. An adapter assembly for selectivelyinterconnecting a surgical loading unit and a handle assembly, theadapter assembly comprising: a drive coupling assembly including: afirst drive element configured to couple to a first drive connector ofthe handle assembly; a second drive element configured to couple to asecond drive connector of the handle assembly; and a third drive elementconfigured to couple to a third drive connector of the handle assembly;and a knob housing coupled to the drive coupling assembly and defining acentral longitudinal axis, wherein the first drive element is disposedon the central longitudinal axis and offset from a plane cooperativelydefined by the second and third drive elements, each of the first,second, and third drive elements being configured to rotate relative tothe knob housing, the third drive element being offset from the seconddrive element.
 2. The adapter assembly according to claim 1, wherein thedrive coupling assembly extends proximally from a proximal end portionof the knob housing.
 3. The adapter assembly according to claim 1,further comprising: a drive nut threadably engaged with a distal portionof the first drive element; and a distal drive member having a proximalportion disposed in mechanical cooperation with a distal portion of thedrive nut.
 4. The adapter assembly according to claim 3, wherein thedistal portion of the first drive element includes external threading,and the drive nut is elongated and has an internal threaded portionmechanically engaged to the external threading of the distal portion ofthe first drive element.
 5. The adapter assembly according to claim 3,wherein the distal drive member is configured to translate withoutrotating in response to a rotation of the first drive element.
 6. Theadapter assembly according to claim 3, wherein each of the drive nut andthe distal drive member is coaxial with the central longitudinal axis ofthe knob housing.
 7. The adapter assembly according to claim 3, whereinthe first drive element defines a longitudinal axis between proximal anddistal ends thereof, and wherein a radial center of each of the firstdrive element, the drive nut, and the distal drive member is disposed onthe longitudinal axis of the drive element.
 8. The adapter assemblyaccording to claim 3, further comprising a pair of thrust bearingsdisposed about the first drive element and proximally of the drive nut.9. The adapter assembly according to claim 3, further comprising alinking assembly mechanically coupling the proximal portion of thedistal drive member and the distal portion of the drive nut.
 10. Theadapter assembly according to claim 9, wherein the linking assemblyincludes a first pin and a second pin, the first and second pins beingdisposed perpendicularly to the central longitudinal axis of the knobhousing and extending partially through the proximal portion of thedistal drive member and the distal portion of the drive nut.
 11. Theadapter assembly according to claim 1, wherein the second and thirddrive elements are radially off-center with respect to the centrallongitudinal axis of the knob housing.
 12. The adapter assemblyaccording to claim 1, further comprising an outer tube extending from adistal portion of the knob housing.
 13. The adapter assembly accordingto claim 12, further comprising a loading unit coupling assemblydisposed on a distal portion of the outer tube.
 14. The adapter assemblyaccording to claim 1, wherein the drive coupling assembly furtherincludes first, second, and third connector sleeves keyed to the first,second, and third drive elements, respectively, such that rotation ofeach of the first, second, and third connector sleeves causesindependent rotation of the first, second, and third drive elements,respectively.
 15. The adapter assembly according to claim 1, wherein thedrive coupling assembly defines a central longitudinal axis that isradially off-center from the central longitudinal axis of the knobhousing.
 16. The adapter assembly according to claim 1, wherein thesecond and third drive elements are disposed on opposite sides of thefirst drive element.
 17. The adapter assembly according to claim 1,wherein the drive coupling assembly further includes a drive couplinghousing extending proximally from the knob housing, each of the first,second, and third drive elements being rotatably supported in the drivecoupling housing.
 18. The adapter assembly according to claim 17,wherein the drive coupling housing defines a central longitudinal axisthat is offset from the central longitudinal axis of the knob housing.19. The adapter assembly according to claim 18, wherein the centrallongitudinal axis of the drive coupling housing extends between thesecond and third drive elements and is on the plane cooperativelydefined by the second and third drive elements.
 20. An adapter assemblyfor selectively interconnecting a surgical loading unit and a handleassembly, the adapter assembly comprising: a drive coupling assemblyincluding: a first drive element configured to couple to a first driveconnector of the handle assembly; a second drive element configured tocouple to a second drive connector of the handle assembly; and a thirddrive element configured to couple to a third drive connector of thehandle assembly; a knob housing coupled to the drive coupling assemblyand defining a central longitudinal axis, wherein the first driveelement is disposed on the central longitudinal axis and offset from aplane cooperatively defined by the second and third drive elements; adrive nut threadably engaged with a distal portion of the first driveelement; a distal drive member having a proximal portion disposed inmechanical cooperation with a distal portion of the drive nut; and alinking assembly mechanically coupling the proximal portion of thedistal drive member and the distal portion of the drive nut, wherein thelinking assembly includes a first pin and a second pin, the first andsecond pins being disposed perpendicularly to the central longitudinalaxis of the knob housing and extending partially through the proximalportion of the distal drive member and the distal portion of the drivenut.